Usage:
Pump Components
(1) Wing nut. (2) Lock washer. (3) Flat washer. (4) Reservoir cover. (5) Stud. (6) Screws. (7) Baffle. (8) Hex nut. (9) Return line baffle. (10) Reinforcing plate. (11) Reservoir. (12) Gasket. (13) Screws. (14) Pin. (15) Cover. (16) Spring. (17) Control valve. (18) O-ring. (19) Plug. (20) Spring. (21) Pressure plate. (22) Pins. (23) Cam ring. (24) Rotor. (25) Vanes. (26) O-ring. (27) O-ring. (28) Body. (29) Needle bearing. (30) Shaft seal. (31) Retaining ring. (32) Bearing. (33) Drive shaft. (34) Key. (35) Retaining ring.
NOTE: Apply a light coat of hydraulic oil to all parts prior to assembly.
1. If needle bearing (29) was removed during disassembly, a new needle bearing must be installed as follows:
a. Make a bearing installation tool from a length of round tubular stock. The outside diameter of the tube must be slightly smaller than the outside diameter of the bearing.
b. Use this tool to press bearing (29) into body (28). The bearing must slide straight into its bore without becoming misaligned. Do not overpress the bearing. Otherwise, damage to the bearing will result.
2. Check the surface of body (28) where rotor (24) will run. This surface must be flat and clean.
3. If shaft seal (30) was removed during disassembly, a new shaft seal must be installed as follows:
a. Make a seal installation tool from a length of round tubular stock. The outside diameter of the tube must be slightly smaller than the outside diameter of the seal. The inside diameter of the tube must be slightly larger than the diameter of the drive shaft.
b. Position seal (30) in body (28) with the closed side of the seal facing the body.
c. Use the above tool to press the seal into place until it engages the shoulder in the body. Do not overpress the seal or it will be damaged.
4. If bearing (32) was removed during disassembly, it must be replaced with a new part as follows:
a. Press bearing (32) onto the drive shaft. Apply force to the inside race of the bearing only.
b. Make sure the bearing is fully seated, and is square with the drive shaft.
c. Install retaining ring (31) onto the drive shaft with the sharp break edge of the retaining ring facing bearing (32). Make sure the retaining ring is seated in its groove in the drive shaft.
5. Lubricate the drive shaft assembly with a little oil. Slide the shaft into body (28). Take care not to damage shaft seal (30) during installation.
6. Install retaining ring (35) onto the end of the drive shaft. Make sure the retaining ring is seated in its groove in body (28).
7. Tap key (34) into place on the drive shaft with a small hammer.
8. Clamp the mounting flange of the body and drive shaft assembly in a vise with drive shaft end facing down.
9. Lubricate two new o-rings (26) and (27). Install the o-rings into their grooves in body (28).
10. Insert vanes (25) into rotor (24) so that the rounded edge of each vane faces away from the rotor. The vanes should fit snugly within the rotor, but must not bind.
11. Lubricate the rotor and vane assembly. Install on splined end of drive shaft, on top of body (28). The counter-bore on rotor (24) must face towards the body.
12. Install two pins (22) into cam ring (23).
13. Place the cam ring over the rotor and vane assembly, on body (28). Make sure the arrow on the side of the cam ring points in the direction of shaft rotation.
14. Install pressure plate (21) over pins (22), against cam ring (23) and the rotor and vane assembly.
15. Set spring (20) on top of pressure plate (21).
16. Install cover (15) onto body (28). Make sure o-rings are not pinched and internal parts are not displaced.
17. Install four screws (13) through cover (15) and into body (28). Tighten the screws in a cross-pattern to 34 to 41 N·m (25 to 30 lb. ft.).
18. Inspect control valve (17) before installing, as follows:
a. Place the round end (38) of the control valve in a vise. Do not hold the control valve in vise by large lands (37).
b. Tighten the vise just enough to prevent the control valve from turning.
c. Use a torque wrench to check the torque of seat plug (36). The seat plug should be tightened to 7 to 8 N·m (5 to 6 lb. ft.).
19. Insert spring (16) into control valve bore of cover (15).
20. Lubricate control valve (17) and install into the control valve bore. Hex-headed seat plug (36) must go in first, facing spring (16). Make sure the seat plug fits inside the spring. The control valve must slide freely within the bore, and show no signs of binding.
21. Install a new o-ring (18) onto plug (19). Slide the plug into cover (15) on top of control valve (17). Press the plug fully in and install pin (14). Tap the pin to lock in place.
22. Install a new gasket (12) on top of cover (15).
23. Set reservoir (11) over gasket (12) make sure the return tube is located at the back of the cover.
24. Set reinforcing plate (10) inside the reservoir with bent edges of the plate facing up. Align the holes in the plate with holes in reservoir.
25. Position return line baffle (9) on the end of stud (5) by nut (8).
26. Thread the stud through reinforcing plate (10) and reservoir (11), into cover (15) about 9.6 mm (.38 in.).
27. Secure baffle (7) inside the reservoir with two screws (6).
28. Tighten nut (8) and screws (6) to 10 to 11 N·m (7.5 to 8 lb. ft.).
29. Install reservoir cover (4), flat washer (3), and lock washer (2) onto the reservoir. Secure with wing nut (1).